BMW K1200LT 1997-2004 Workshop Service Manual Repair
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🏷️ Basic Information Identification Make: BMW Model: K1200LT Year: 1997-2004 👋 Introduction Market Position Market Position: Luxury touring motorcycle, flagship model for BMW Motorrad in its segment during the specified years. Competitive Analysis Competitors: Honda Gold Wing, Harley-Davidson Electra Glide, Kawasaki Voyager, Yamaha Royal Star Venture. Key Features Key Features Vehicle: Opposed-four-cylinder engine, shaft drive, extensive fairing for weather protection, integrated audio system, cruise control, electric reverse, ample luggage capacity. Key Features Manual: Detailed procedural steps, clear diagrams and illustrations, comprehensive troubleshooting guides, specifications and tolerances. 📋 Manual Details Coverage Areas Coverage: Complete workshop service and repair Page Count Page Count: Estimated 700-900 pages (typical for comprehensive workshop manuals of this era) Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel injection (EFI), ignition, cooling, exhaust, lubrication, starting and charging Transmission Drivetrain: Clutch, gearbox, final drive (shaft drive), transmission fluid Chassis Suspension: Front fork (telelever), rear suspension (paralever), wheel bearings, steering head bearings Braking System: Front and rear brake systems (ABS functionality, fluid, caliper service, disc replacement) Electrical System: Wiring diagrams, lighting, battery, charging system, starter motor, electronic control units (ECUs), diagnostics Bodywork Body Panels: Fairings, luggage systems, seats, body panel removal and installation Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, coolant flushes, brake fluid changes, spark plug replacement Repair Procedures: Engine overhaul, transmission rebuild, suspension servicing, electrical component replacement, brake system repairs Troubleshooting Diagnostics: Step-by-step diagnostic guides, fault code interpretation, common problem identification Torque Specifications: Detailed torque values for all critical fasteners Technical Depth Depth: Comprehensive: covers everything from routine maintenance to full engine and component rebuilds, including electrical diagnostics and tuning adjustments. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans with clear diagrams and text, suitable for printing. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, Boxer-twin (opposed-four cylinder configuration, though often referred to as a Boxer-twin due to engine layout), DOHC, 4 valves per cylinder. Displacement: 1171 cc (later models 1172 cc) Bore X Stroke: Approx. 78.8 mm x 70.5 mm (varies slightly by model year) Compression Ratio: Approx. 10.5:1 Performance Horsepower: Approx. 98-100 hp @ 7500 rpm Torque: Approx. 101-103 Nm (74.5-75.9 lb-ft) @ 5250-5500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Motronic Fuel Type: Unleaded gasoline, minimum 95 octane (RON) 🔧 Transmission Standard Transmission Type: 5-speed manual gearbox Final Drive: Shaft drive Features Clutch Type: Hydraulically operated, multi-plate wet clutch Reverse Gear: Electric reverse, powered by the starter motor. 📐 Dimensions Exterior Length: Approx. 2465 mm (97.0 in) Width: Approx. 960 mm (37.8 in) (excluding mirrors) Height: Approx. 1540 mm (60.6 in) (with windscreen) Weights Dry Weight: Approx. 303 kg (668 lbs) Wet Weight: Approx. 323 kg (712 lbs) (fully fueled and ready to ride) Payload Capacity: Approx. 219 kg (483 lbs) Fuel Capacity: 21 liters (5.5 US gal), including a 3.5 liter reserve 🛡️ Safety Features Ratings ABS System: Integral ABS (Anti-lock Braking System) - standard on most models. Active Features Lighting: Halogen headlights, integrated turn signals, hazard lights. Passive Features Chassis Design: Sturdy aluminum frame and robust suspension systems contribute to stability. Braking Performance: Dual disc front brakes with 4-piston calipers, single disc rear brake with 2-piston caliper, backed by ABS. 💡 Technology Features Infotainment Audio System: Integrated radio/cassette (later models CD player) with speakers, often with handlebar controls. Ability to connect external music players (e.g., via AUX input on some models). Cruise Control: Standard electronic cruise control. Driver Assistance ABS: Integral ABS (Anti-lock Braking System). Connectivity Diagnostics: BMW's proprietary diagnostic connector for engine management and ABS system checks. Electrical Complexity: Significant electrical system due to comprehensive features (audio, cruise control, ABS, heated grips/seats). 🔧 Maintenance Service Intervals Oil Change Interval: Every 10,000 km (6,000 miles) or annually, whichever comes first. Filter Replacement: Oil filter: With every oil change. Air filter: Inspect every 10,000 km, replace as needed or at 20,000 km. Spark Plug Replacement: Every 20,000 km (12,000 miles). Brake Fluid Change: Every 2 years, regardless of mileage. Valve Clearance Check: First check at 20,000 km, then every 40,000 km (24,000 miles). Fluid Specifications Engine Oil Type: BMW recommends SAE 5W-40 synthetic or semi-synthetic motorcycle oil meeting BMW approval (e.g., BMW Longlife-04, but check specific manual for older approvals). Check viscosity based on ambient temperature. Engine Oil Capacity: Approx. 4.0 liters (4.2 US quarts) with filter change. Coolant Type: BMW approved coolant, typically a mixture of ethylene glycol and distilled water (50/50 ratio). Brake Fluid Type: DOT 4 brake fluid. Final Drive Oil Type: BMW recommends SAE 75W-90 synthetic gear oil for the final drive. Known Issues Known Issues: Consistent voltage regulator failures, alternator issues, ABS modulator problems,...
Step-by-step diagnostic guides, fault code interpretation, common problem identification
Torque Specifications:
Detailed torque values for all critical fasteners
Technical Depth
Depth:
Comprehensive: covers everything from routine maintenance to full engine and component rebuilds, including electrical diagnostics and tuning adjustments.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans with clear diagrams and text, suitable for printing.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, Boxer-twin (opposed-four cylinder configuration, though often referred to as a Boxer-twin due to engine layout), DOHC, 4 valves per cylinder.
Displacement:
1171 cc (later models 1172 cc)
Bore X Stroke:
Approx. 78.8 mm x 70.5 mm (varies slightly by model year)
Sturdy aluminum frame and robust suspension systems contribute to stability.
Braking Performance:
Dual disc front brakes with 4-piston calipers, single disc rear brake with 2-piston caliper, backed by ABS.
💡 Technology Features
Infotainment
Audio System:
Integrated radio/cassette (later models CD player) with speakers, often with handlebar controls. Ability to connect external music players (e.g., via AUX input on some models).
Cruise Control:
Standard electronic cruise control.
Driver Assistance
ABS:
Integral ABS (Anti-lock Braking System).
Connectivity
Diagnostics:
BMW's proprietary diagnostic connector for engine management and ABS system checks.
Electrical Complexity:
Significant electrical system due to comprehensive features (audio, cruise control, ABS, heated grips/seats).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually, whichever comes first.
Filter Replacement:
Oil filter: With every oil change. Air filter: Inspect every 10,000 km, replace as needed or at 20,000 km.
Spark Plug Replacement:
Every 20,000 km (12,000 miles).
Brake Fluid Change:
Every 2 years, regardless of mileage.
Valve Clearance Check:
First check at 20,000 km, then every 40,000 km (24,000 miles).
Fluid Specifications
Engine Oil Type:
BMW recommends SAE 5W-40 synthetic or semi-synthetic motorcycle oil meeting BMW approval (e.g., BMW Longlife-04, but check specific manual for older approvals). Check viscosity based on ambient temperature.
Engine Oil Capacity:
Approx. 4.0 liters (4.2 US quarts) with filter change.
Coolant Type:
BMW approved coolant, typically a mixture of ethylene glycol and distilled water (50/50 ratio).
Brake Fluid Type:
DOT 4 brake fluid.
Final Drive Oil Type:
BMW recommends SAE 75W-90 synthetic gear oil for the final drive.
BMW Motorrad has a long history of producing high-quality, technologically advanced motorcycles, particularly known for its Boxer engines and touring capabilities.
Model Evolution
Model Lineage:
The K1200LT evolved from earlier K-series inline-four and flat-four models, specifically building upon the success of the K1100LT and K1200RS, adapting the platform for ultimate long-distance touring.
Production
Production Years:
1997-2004
Manufacturing Location:
Berlin, Germany
🏆 Awards & Recognition
Recognitions
Awards:
While specific annual awards are not readily documented, the K1200LT was consistently lauded by motorcycle publications for its comfort, performance, and touring prowess, often being ranked among the top luxury touring motorcycles.
Ratings
Consumer Ratings:
Generally received high marks for comfort, handling for its size, and long-distance capability.
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